Another Floor Lamp #6: Progress on the Base

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This is part 6 in a 6 part series: Another Floor Lamp

  1. Starting Small
...
  1. Testing the Lighting Plan
  2. Progress on the Base

I started with some cherry, surfaced down to just under 1 inch thick, edged glued two pieces for the necessary width, which would then be cut in half and stacked double to achieve the desired base thickness.  It took a couple days to refine the CNC cut plan for the base.   Originally, I thought I'd need to route wiring channels on the underside of the top disc, which would then be enclosed by the bottom disc, so the plan from early-on was to mill two separate discs and then glue them together.   By the time I had worked out all of the necessary pockets, that wasn't necessary and I could have glued the double-thick blank prior to milling.  But since the sequence was already stuck in my head, I didn't consider I could have changed it until after I had cut the discs.  No matter, it worked out fine anyway.

The left is the bottom disc, the right is the top disc.   The milling was to the underside surface of both.


I cleaned-up the cut edges with a small file and some sandpaper.  The shallow diagonal channel in the bottom of the driver pocket is for the wires that go to the LEDs.


In the top disc, the pocket for the dimmer has a recess for a 1" washer, which will get CA glued in place.  This is for the shaft of the rotary dimmer.  The smaller rectangular hole is for a rocker switch that will snap-in from the outside.  You can just see a lip at the bottom of the hole that the switch will snap past when pressed in place.


Test fitting.

I'm not pressing that rocker switch in until I'm wiring it up.  They're a bear to pop out and I don't want to damage that little lip that holds it in place.  I might make a wood knob for the dimmer at some point.


The driver has some space extra around it for the wiring.  The finished base will get some feet around the perimeter to get some air flow to the driver.   I haven't worked out the feet yet.


The 1/4" locator pins will index matching holes in the bottom disc.  These ensure that the discs won't shift around when gluing.  The inner three 3/8" holes are for dowels that will join the bottom of the staves to the base.   The center hole is for the lamp pipe, with a counterbore for a washer and nut and also to provide clearance for the wires that will run to the LEDs


A rubber roller is great for applying a uniform coat of glue.


All glued and clamped.


Tomorrow, I'll remove the clamps and do some shaping.